AutomationDirect IRON HORSE GSD5 Series User manual

Page 1IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020
™



Page 2 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020
~WARNING ~
Thank you for purchasing automation equipment from Automationdirect.com®, doing business as
AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or
uses this equipment should read this publication (and any other relevant publications) before installing or
operating the equipment.
To minimize the risk of potential safety problems, you should follow all applicable local and national codes
that regulate the installation and operation of your equipment. These codes vary from area to area and
usually change with time. It is your responsibility to determine which codes should be followed, and to verify
that the equipment, installation, and operation is in compliance with the latest revision of these codes.
At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code,
and the codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or
government offices that can also help determine which codes and standards are necessary for safe installation
and operation.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and
standards. We do not guarantee the products described in this publication are suitable for your particular
application, nor do we assume any responsibility for your product design, installation, or operation.
Our products are not fault-tolerant and are not designed, manufactured or intended for use or resale as
on-line control equipment in hazardous environments requiring fail-safe performance, such as in the
operation of nuclear facilities, aircraft navigation or communication systems, air traffic control, direct life
support machines, or weapons systems, in which the failure of the product could lead directly to death,
personal injury, or severe physical or environmental damage (“High Risk Activities”). AutomationDirect
specifically disclaims any expressed or implied warranty of fitness for High Risk Activities.
For additional warranty and safety information, see the Terms and Conditions section of our catalog. If you
have any questions concerning the installation or operation of this equipment, or if you need additional
information, please call us at 770-844-4200.
This publication is based on information that was available at the time it was printed. At AutomationDirect
we constantly strive to improve our products and services, so we reserve the right to make changes to the
products and/or publications at any time without notice and without any obligation. This publication may
also discuss features that may not be available in certain revisions of the product.

This publication may contain references to products produced and/or offered by other companies. The
product and company names may be trademarked and are the sole property of their respective owners.
AutomationDirect disclaims any proprietary interest in the marks and names of others.
Copyright© 2013-2020 Automationdirect.com® Incorporated
All Rights Reserved
No part of this manual shall be copied, reproduced, or transmitted in any way without the prior, written
consent of Automationdirect.com®Incorporated. AutomationDirect retains the exclusive rights to all
information included in this document.

Page 3IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020

GSD5 Series DC Drives User Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
~WARNING ~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GSD5 DC Drives User Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IronHorse GSD5 Series DC Drives General Information . . . . . . . . . . . . . . . . . . . . . . . . . 4
Selection and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Trim Pot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
GSD5 Series Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15


The IronHorse GSD5 Series DC Drives User Manual describes the installation, configuration, and
methods of operation of the GSD5 Series DC Drives.
All information contained in this manual is intended to be correct. However, information and data
in this manual are subject to change without notice. AutomationDirect (ADC) makes no warranty of
any kind with regard to this information or data. Further, ADC is not responsible for any omissions or
errors or consequential damage caused by the user of the product. ADC reserves the right to make
manufacturing changes which may not be included in this manual.

This manual contains important information for those who will install, maintain, and/or operate any
of the GSD5 Series DC Drives.

By Telephone: [phone] (Mon.–Fri., 9:00 a.m.–6:00 p.m. E.T.)
On the Web: www.automationdirect.com
Our technical support group is glad to work with you in answering your questions. If you cannot
find the solution to your particular application, or, if for any reason you need additional technical
assistance, please call Technical Support at 770-844-4200. We are available weekdays from 9:00 a.m.
to 6:00 p.m. Eastern Time.
We also encourage you to visit our web site where you can find technical and non-technical
information about our products and our company. Visit us at www.automationdirect.com.

When you see the “notepad” icon in the left-hand margin, the paragraph to its immediate right will
be a special note.
When you see the “exclamation mark” icon in the left-hand margin, the paragraph to its immediate right Will be a
Warning. this information could prevent injury, loss of property, or even death (in extreme cases).

Page 4 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020

IronHorse GSD5 DC drives are versatile, general-purpose, variable-speed, DC motor controllers that
are designed to control DC Permanent Magnet, Shunt Wound, and some Universal (AC/DC) motors.
Incoming AC voltage is converted to adjustable full-wave rectified DC voltage to operate the DC motor.
Also, a full-wave field voltage is provided for shunt wound motors.
Carefully check the DC Drive for shipping damage. Report any damage to the carrier immediately.
Do not attempt to operate the drive if visible damage is evident to either the circuit or to the
electronic components.

• Input voltages 120/240VAC @ 50/60Hz; output 0–90/180VDC.
• Adjustable horsepower settings (1/8 thru 1hp @ 120 VAC input; 1/4 thru 2hp @ 240 VAC input).
• Barrier terminal strip for all power and control wiring.
• Full-wave bridge supply.
• 1% speed regulation with armature voltage feedback; ±1/2% with tachometer feedback.
• Adjustable Minimum speed, Maximum speed, IR Compensation, Current Limit, and Acceleration &
Deceleration.
• Line voltage compensation.
• 5kΩ speed potentiometer with leads, dial, and knob included.
• 50:1 speed range.
• Transient voltage protection.
• Voltage following mode or DC tachometer follower by supplying ungrounded 0–12VDC analog input
signal.
• DC tachometer feedback (6V at base speed).
• Inhibit circuit permits start & stop without breaking AC lines.
• Shunt field supply provided.
• Available in NEMA 4/12 enclosure with Power ON/OFF switch, or open-frame chassis.

MINIMUM SPEED – Allows adjustment of the motor speed when the speed pot is set at minimum
(CCW). This permits the user to eliminate “Deadband” on the main speed control, permitting zero
calibration. Clockwise rotation of “MIN” trim pot increases speed.
MAX SPEED (Maximum Speed) – Allows adjustment of the motor speed when the speed pot is set at
maximum (CW). This permits the user to eliminate the top end “Deadband”, which will provide full
speed at maximum rotation. Rotation of the “MAX” trim pot in the clockwise direction increases the
maximum motor speed.
ACCEL (Acceleration) – Allows adjustment of the motor acceleration from a minimum of 0.5 seconds to
approximately 8.0 seconds. The deceleration time is proportional to the ACCEL setting.
I.R. COMP (Speed Regulation) – Adjusts the drive output to compensate for speed changes caused by
varying motor loads. As motor load is increased, IR COMP increases the voltage output of the drive.
Clockwise rotation of the “IR COMP” trim pot increases compensation.
CUR. LIM. (Current Limit) – Provides protection from excessive armature current by limiting the
maximum armature current the drive can provide. This enables adjustment of the maximum torque
the motor can deliver. Torque adjustment (CUR. LIM.) is preset at 125% of rated motor torque
(current) based on horsepower. Clockwise rotation of the “CUR. LIM.” trim pot increases the torque
(current) the drive will provide.
INHIBIT TERMINAL PIN – An adjustable acceleration ramp that allows the user a choice of stopping and
starting hard (fast), or stopping hard with a soft start (without breaking the AC lines).

Page 5IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020

GSD5 Series DC Drives – Selection & Specifications
  







 open frame NEMA 4/12
 1.4
 None Current follower Manual reversing Voltage follower
 120/240 VAC ±10%
 0–90/180 VDC
 100VDC @ 120VAC input; 200VDC @ 240VAC input; (1A max)
 1/8 – 1 hp @ 90VDC ; 1/4 – 2 hp @ 180VDC
 150mA – 10.8A (DC)
 150% for 60s
 1–15A (DC)
 Metal Oxide Varistor (MOV)
 Adjustable


 5kΩ 2W potentiometer or 0–10VDC isolated input signal

4–20mA with
option GSDA-
AI-A or -V5
n/a 4–20mA n/a 4–20mA

0-5VDC,
0-250VDC with
option GSDA-
AI-V5
n/a n/a n/a 0-5VDC,
0-250VDC
 50:1
 ±1% of base speed (0.5% with tachometer feedback)
 Adjustable from 66% to 110% of base speed
 Linear ramp 0–30% of adjustable maximum speed
 Linear ramp adjustable 0.5–8s
 Adjustable 0.06–80s (dependent on acceleration time setting)
 No
 No
 Barrier-type terminal strip; 26–12 AWG
 Bussman ABC or Littlefuse 314 series ceramic fuses or equivalent
Refer to wiring diagrams for details
 -10 to 45 °C [14 to 113 °F]
 Current limiting
 Can be mounted in any orientation
 NOT compatible with any corrosive gases
 16.25 oz [413g] 25.50 oz [723g]
 CULUS listed (E333109), RoHS RoHS
Optional Accessories *
Replacement Potentiometer GSDA-5K
Digital Potentiometer GSDA-DP
Manual Reverse Switch GSDA-MREV**** Included GSDA-MREV***
Analog Current Input Card GSDA-AI-A – Included – –
Analog Voltage Input Card GSDA-AI-V5 – – – Included
* For accessories details, refer to the "GSD Series DC Drives Accessories" section.
** Plugging is a method of rapidly changing motor direction by reversing motor armature polarity, while the motor is still
running.
*** Fuse type: Bussman/Edison ABC, Littlefuse 314 series, or equivalent. Fuse hot legs only; do not fuse AC neutrals. Refer
to “Fusing” on page 7.
****To meet NEMA4 requirements, GSDA-MREV requires a user provided external exclosure.

Page 6 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020






Page 7IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020

Install open-frame drives in an enclosure with a volume at least three times the volume of the open-
frame drive.
Do not mount GSD5-240-xxxxx DC drive where ambient temperature is outside the range of -10 to 45
°C (14 to 113 °F).
Size all wires that carry armature or line currents as specified by applicable national, state, and/or
local codes. All other wires may be 18AWG or smaller as permitted by the codes.
Separate control wires from the armature and AC lines when routed in conduit or wire trays.
caution!! turn poWer off While making Wiring connections.
improper installation or operation of this dc drive may cause injury to personnel or drive failure. the drive
must be installed in accordance With local, state, and national safety codes. make certain that the poWer supply
is disconnected before attempting to service or remove any components!!! ifthe poWer disconnect point is out of
sight, lock it in disconnected position and tag it to prevent unexpected application of poWer. only aqualified
electrician or service personnel should perform any electrical troubleshooting or maintenance. atno time
should circuit continuity be checked by shorting terminals With ascreWdriver or other metal device.
before attempting to Wire the dc drive, make sure all poWer is disconnected. recheck code designation to
assure proper voltage is present for the dc drive. carefully select proper Wire size for current and voltage
drop. limit the voltage drop through the Wiring to 5% of the line voltage at full load
caution!! donot attempt to perform ahi-pot test across the ac lines With the dc drive in the circuit. this
Will result in immediate or long-term damage to the drive.
1) ensure that the gsd5 drive chassis is properly grounded.
2) motor armature connections must not be sWitched or broken While the gsd5 drive is on.
serious damage may result.
3) the inputs to the speed pot terminals (p1-1, p1-2, p1-3) must not be grounded.
serious damage may result.

The GSD5 has an internal fuse in AC line 1 (P1-11), and this fuse is sized to open in the event of a
shorted armature or if an armature line is shorted to earth ground. For properly connected 120
VAC input, additional fusing is not needed. [Replace with Bussman ABC10 or LittelFuse 314-010 or
equivalent. AutomationDirect sells ABC series fuses.]
For 240 VAC applications, use an external fuse in AC line 2 (P1-10). This fuse should be a Bussman
ABC10 or LittelFuse 314-010. [AutomationDirect sells ABC series fuses.]
AC current is determined by motor characteristics, and it may be necessary to increase fuse value for
some applications.

GSD5 Wiring Terminals
  
barrier-type terminal strip 26–12 AWG 10.0 lb·in [1.1 N·m]

Page 8 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020



Customer Installed
Speedpot
(factory provided
with 8-inch leads)
P2
Min Max Accel
IR
Comp
Cur
Lim
Inhibit
Pin
orange white
red
1234567891011P1
motor
armature
chassis
ground
field* AC input **
Pot Lo
Wiper
Pot Hi
–Arm
+Arm
+Field
–Field
spare spare
AC2 AC1
* Field terminals are used for shunt-wound motors only!
Do not connect these terminals when using permanent-magnet motors.
** AC1 terminal is internally fused; AC2 terminal is NOT internally fused.
Add external fuse for AC2 if it is connected to a hot AC line.

Arm2
Arm1
AC2* (N)
AC1* (L)
-Armature / -Field (P1-4)
+Armature (P1-5)
VAC Input (N) (P1-10)*
VAC Input (L) (P1-11)*
GSD5-240-10C
* AC1 (P1-11) terminal is internally fused;
AC2 (P1-10) terminal is NOT internally fused.
Add external fuse for AC2 if it is connected
to a hot AC line.
OFF (no wire terminal)
Direction 1 (forward or reverse)
Direction 2 (reverse or forward)
Customer supplied
4PDT Center-off
Center-Blocked switch
(GSDA-MREV shown)

Page 9IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020


SPEEDPOT
DPST SWITCH
-11
-9-8-4 -5 -6 -7-1 -2 -3
P2
Inhibit
Pin
P1
Pot Lo
Wiper
Pot Hi
-Arm
+Arm
+Field
-Field
AC
AC
motor
armature ac input**
field*
chassis
ground
Switched AC2
Switched AC1
Min Max Accel
IR
Comp
Cur.
Lim. LO (orange)
HI (white)
WIPER (red)
(white)
-10
* Field terminals are used for shunt-wound motors only!
Do not connect these terminals when using
permanent-magnet motors.
** AC1 terminal is internally fused; AC2 terminal is NOT
internally fused. Add external fuse for AC2 if it is
connected to a hot AC line.
Endplate with holes for 1/2" NPT conduit
INSIDE OF COVER
(black
or brown)
(black)
(white
or
yellow)
FACTORY PREWIRING
CUSTOMER WIRING
 
3PDT Switch
motor ac input
INPUT IMPEDANCE:
1.2MWon high scale
150KWon low scale
-4 -5 -6 -7
P2
Inhibit
Pin
P1
Pot Lo
Wiper
Pot Hi
-Arm
+Arm
+Field
-Field
AC AC
Switched AC Switched AC
Min Max Accel
IR
Comp
Cur.
Lim.
-11-9-8 -10-1 -2
Speedpot
(white)
(red)
(yellow)
(brown)
(black)
(blue)
(black)
(red)
(brown)
(yellow)
P2
P4
P3
P5
JP2
-1 -2 -3
4-20 Vin
RANGE
JUMPER
CONNECTOR*
GAIN
TRIMPOT
(white) (orange)
(orange)
(white)
BALANCE
TRIMPOT
(white)
Vin or 4-20mA
CONNECTOR
-1 -3
NOTE: SOME
FACTORY WIRING
IS NOT SHOWN
FOR CLARITY
analog
speed
signal
analog
speed
common
* Jumper clip is used to select
input voltage range. When
installed from P4-1 to P4-2,
the range is 0–25 VDC thru
0–250 VDC. When installed
from P4-2 to P4-3, the range
is 0–5 VDC thru 0–25 VDC.
FACTORY PREWIRING
GSD5-240-10N4-V
(INSIDE OF COVER)
CUSTOMER WIRING

Page 10 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020

 
The GSD5-240-10N4-R includes a 4PDT blocked center switch which permits reversing the motor.
When switched between the forward/reverse positions, a delay is encountered due to the blocked
center position, which protects the control from any voltage that may be at the armature terminals.
The center position is OFF/NEUTRAL.
caution: the motor must come to acomplete stop before changing directions. ifthe motor does not
come to acomplete stop, the drive may be seriously damaged. bypassing the center block of the sWitch
may result in serious damage to the drive.
INSIDE OF COVER
SPEEDPOT
4PDT SWITCH
(black)
Endplate with holes for 1/2" NPT conduit
-11-9-8-4 -5 -6 -7-1 -2 -3
P2
Inhibit
Pin
P1
Pot Lo
Wiper
Pot Hi
+Field
-Field
AC
AC
motor
armature ac input
field*
chassis
ground
Switched AC2
Switched AC1
Min Max Accel
IR
Comp
Cur.
Lim. LO (orange)
HI (white)
WIPER (red)
(white)
-10
-Arm
+Arm
brown)
(yellow)
(purple)
(gray)
(blue)
(red)
-1 -2
P3
* Field terminals are used for shunt-wound motors only!
Do not connect these terminals when using
permanent-magnet motors.
** AC1 terminal is internally fused; AC2 terminal is NOT
internally fused. Add external fuse for AC2 if it is
connected to a hot AC line.
P3-1 P3-2 P1-8 P1-9
P1-4 P1-5 P1-10 P1-11
AC INPUTARM INPUT
-7
-6
-3
-2
-1
P1 4PDT SWITCH
P3
-4
-11
-10
-5
-2
-1
-9
-8
ARM 1
ARM 2
AC
AC
black
white
brown
yellow
red
blue
purple
or brown
gray or
yellow
brown
yellow
purple
or brown
gray or
yellow
 
The GSD5-240-10N4-A includes a 4–20 mA isolated signal card that allows the drive to be run in either
the Manual mode via a speed pot, or the Auto mode via the 4–20 mA signal.
-7-6-5-4 P1
AUTO
MANUAL
-11-9
3PDT
SWITCH
-10-8
CURRENT
SOURCE
LINEARITY/GAIN
ADJUSTMENT
BALANCE
ADJUSTMENT
(GSD5 TERMINAL STRIP)
from P1-2 of GSD5
AC AC
-3-2-1
+-
P16
250/500
125
JU1
JU3
JU2
YELLOW
RED
ORANGE
HI
W
LO
WHITE
RED
SPEEDPOT

Page 11IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020


Two-speed operation is done using
two 10 kΩ speed potentiometers in
parallel, with both Highs connected
to terminal P1-3, and both Lows
connected to P1-1. A SPDT switch
selects which pot Wiper is connected
to terminal P1-2.
(2) 10kΩ Speedpots
P1
1
2
3
LO
HI
W
LO
HI
W
SPDT
GSD5-xxx-xxxx

A DPDT switch is used to control and to connect a
customer-supplied Dynamic Braking Resistor (DBR).
Typical values for the DBR are 35–50W at 5Ω for 120V,
or 10Ω for 240V. Motor horsepower, inertia, and cycle
time affect the sizing of the DBR.
W
LO
HI
MOTOR
DYNAMIC
BRAKE
RESISTOR
DPDT SWITCH (N.C.)
1
2
3
4
5
6
P1
GSD5- xxx-xxxx
P2 INHIBIT

Improves regulation to ± 1/2 of base speed.
6VDC at Base Speed (3VDC at
1000 rpm for 1800 rpm motor)
P2 Inhibit
P1-4 -Arm
Tachometer
+
–

Allows drive output to follow tachometer
voltage.
12 VDC at Full Speed
P1-2 Pot Wiper
P1-1 Pot Lo
Tachometer
+
–
Tachometer control needs tachometer output of 7VDC/1000rpm with ripple limited to 1% or
less.

The customer-supplied SPST switch is
connected in series between the Speed Pot
High (P1-3) and the Inhibit pin (P2). To Inhibit
(stop motor), close Speed Pot High to the
Inhibit pin. To restart, return the switch to
open. NOTE: The control will stop and start
fast; Accel is bypassed.
SPST
SPEEDPOT WIPER
LO
HI
P1
1
2
3
INHIBIT
(P2)

The common of the SPDT switch is connected
to control pot High, and is switched between
Speed Pot High (P1-3) and the Inhibit pin
(P2). To inhibit (stop motor), Speed Pot High
is closed to the Inhibit pin. To restart, return
the switch to Speed Pot High. NOTE: The
control will stop fast and soft start through a
fixed acceleration rangee.
SPDT
SPEEDPOT
WIPER
LO
HI
P1
1
2
3
INHIBIT
(P2)
1) Inhibit control will stop and start the motor quickly.
2) Inhibit control permits starting and stopping the motor without breaking the AC lines.
3) In the event of SCR failure or false triggering, the Inhibit circuit will not stop the motor.
4) Always use shielded wire when connecting to the Inhibit terminal, and connect the shield
to the -Armature or Common of the drive.

Page 12 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020

1) Recheck all wiring. Accidental grounds, loose or pinched wires on armature or speed pot wires may
damage the DC drive when power is applied.
2) Check to see that the incoming power is of the correct voltage.
3) Turn the speed pot to zero (fully CCW).
4) Turn power on, and advance the speed pot while observing motor direction of rotation.
Power must be turned off again before step 5 can be accomplished!
5) If the motor rotation is incorrect, turn power off at external disconnect, and reverse the +ARM and
-ARM connections.
6) Check for satisfactory operation throughout the speed range.
7) If operation is satisfactory, no readjustments are needed.
8) If instability or surging is observed, or if maximum speed is higher than desired, refer to the “Trim
Pot Adjustments” section.”
9) For other problems, consult the “Troubleshooting” section.

If the system is unstable after the previous Start-Up procedure, then adjust the trimpots as follows.
These adjustments are maintained, and periodic readjustments are not normally needed. However,
readjustments could be needed if the drive is operated beyond ±10% of the rated line voltage.

GSD5-240-10C, GSD5-240-10N4, GSD5-240-10N4-R Trim Pot Adjustment *
  

Sets maximum motor speed
when speed pot is set at
maximum (fully CW rotation).
CW rotation of MAX trim pot
increases maximum motor
speed.
1) TURN DRIVE POWER OFF!!
2) Connect a DC voltmeter: + to +ARM; - to -ARM.
3) Set meter voltage range: (90 VDC for 120 VAC; 180 VDC for 240 VAC).
4) Turn power on. Set Speed pot at 100%.
5) Adjust MAX trim pot to rated motor armature voltage as shown on meter.
NOTE: A tachometer or strobe may be used in lieu of a meter. Follow above
steps, except adjust MAX trim pot to rated motor base speed indicated by
tachometer or strobe.

Sets minimum motor speed
when speed pot is set at zero.
CW rotation will increase
minimum motor speed.
1) Set Speed pot to zero (fully CCW).
2) Rotate MIN trim pot CW until motor starts to rotate.
3) Slowly rotate MIN trim pot CCW until motor stops.
NOTE: If motor rotation is desired, rotate MIN trim pot CW until desired
MIN speed is reached.

Calibrates speed regulation.
Provides a means of
improving motor speed
regulation in the armature
feedback mode. If a
slowdown due to load change
is of no concern, rotate this
trim pot fully CCW.
1) Set Speed pot at 50%.
2) Observe motor speed at no load condition.
3) Apply full load to motor.
4) Turn IR COMP trim pot CW to obtain the same motor speed as with no load.

Limits DC motor armature
current (torque) to prevent
damage to the motor or
drive. The current limit is set
for the rated motor current.
CW rotation of this trim pot
increases the armature current
(or torque produced).
1) TURN DRIVE POWER OFF!
2) Connect a DC Ammeter between A1 on motor and +ARM on drive. This is
in series with the motor.
3) Turn power ON.
4) Set Speed pot at the 50% position.
5) Apply friction braking to motor shaft until motor stalls (zero rpm).
6) With motor stalled, set current at 125% of rated motor armature current by
adjusting CUR. LIM. trim pot.
 Allows adjustment of
acceleration by user. CW rotation of the ACCEL trim pot increases acceleration time.
* Adjustments are performed with motor connected to drive.
DO NOT USE this adjustment procedure for GSD5-240-10C DC drives with GSDA-AI-A analog current input cards, for
GSD5-240-10N4-A drives, or for GSD5-240-10N4-V drives.
** For Max and Min adjustments of the GSD5-240-10C DC drive with GSDA-AI-A analog input cards, the GSD5-240-
10N4-A drive, or the GSD5-240-10N4-V drive, refer to the adjustment procedures on the following page.

Page 13IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020


(Adjustments are performed with motor connected to drive.)
1) Adjust the DC drive Min trim pot to minimum (full CCW) and Max trim pot to 50%. (The voltage is
set below the typical motor voltage to make certain the drive is NOT in saturation before setting the
analog current input board saturation point.
2) Set the Linearity/gain pot on the analog current input full CW. This is a 20-turn pot and you should
hear a clicking with each turn when fully up or just count 20 turns.
3) Make certain your motor is connected to +/-ARM output of the drive, the AUTO/MAN switch is in
AUTO mode (for GSD5-240-10N4-A), and source power for the drive is turned on. (Note: For proper
tuning, this setup is best done on an unloaded motor.)
4) With power applied and a voltmeter monitoring motor output VDC, apply 4mA to analog current
input board. Check voltmeter reading and adjust the Linearity/gain trim pot, R16, on the analog
current input board CCW until motor output voltage is less than 0.1VDC.
5) Now apply 20mA to the analog current input board and adjust the Max trim pot to a voltage that
is 15 volts above the final desired max motor voltage output. Adjust the Linearity/gain trim pot on
the analog current input board CCW until the motor output voltage decreases to the desired max
voltage setpoint.
6) Now, apply 4mA to the analog current input board again, and adjust the Min trim pot to deadband
or the desired minimum motor voltage output. The deadband point is where you are at 0VDC, and
any further increase of the Min trim pot would result in an output to the motor. Re-apply 20mA to
the analog current input board and verify max output has not changed. A small adjustment may be
needed to the Max trim pot to reset to desired max output.
7) Adjust 4-20 input to 12mA. If tuned properly the output voltage of an unloaded motor should be
within a few volts of ½ output (based on max output setting above).
8) : With 20mA applied to the GSD5-240-10N4-A in Auto mode,
move AUTO/MANUAL switch to MANUAL.
In manual mode, turn the speed pot full CW and note motor voltage output reading on voltmeter.
If not equal to output at 20mA in Auto Mode, adjust the Balance trim pot on the GSD5-240-10N4-A
board (CW or CCW) until the same reading is achieved. The motor output VDC should not change
more than 1VDC when flipping back and forth between AUTO and MANUAL position.

(Adjustments are performed with motor connected to drive.)
1) With NO power at the drive, connect a DC voltmeter (meter must not be grounded) to control
outputs as follows: Meter COMMON to the -ARM terminal; Meter POSITIVE to the +ARM terminal.
Select correct meter range (0-90V or 0-180V).
2) Preset GAIN trim pot (analog voltage follower board) fully CCW, place input voltage range jumper
clip in proper position. (For ranges, refer to the GSD5-240-10N4-V Basic Wiring Diagram on page
9.)
3) Preset control as follows: MIN and IR COMP fully CCW; MAX at 50%.
4) Apply desired AC voltage to drive and analog voltage follower board.
5) With 0 volts into analog voltage follower board, adjust MIN trim pot on drive to eliminate
deadband. To do this, increase MIN fully CW, and then adjust CCW until meter reads 0V.
6) Apply maximum input voltage to analog voltage follower board input.
7) Adjust GAIN until no further change in voltage output occurs, then turn CCW until a 5V drop occurs,
and then set control MAX to 90VDC (for 120V input) or 180VDC (for 240V input).
8) For Closed Loop systems the IR COMP should remain fully CCW. For Open Loop systems, set IR per
set-up procedure.
9) Some interaction between trimpots may occur. Recheck the MIN trim pot setting and repeat steps 5
through 7 as needed.

Page 14 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020

If a newly installed DC Drive will not operate, it is likely that a terminal connection is loose. Check the
terminal connections and ensure that they are secure and correct. If the drive is still inoperative, refer
to the Troubleshooting Table.
Troubleshooting
  

1) Blown fuse or circuit breaker
2) Incorrect or no power
3) Speed pot set at zero
4) Worn motor brushes
1) Replace fuse or reset breaker
2) Install proper power service
3) Rotate Speed pot CW to start
4) Replace motor brushes




1) No motor or load connected
2) Speed pot low connection open
1) Ensure that motor or load is connected to
armature terminals
2) Ensure that Speed pot Low wire is connected



1) Low voltage
2) Overload condition
3) Worn motor brushes
4) Max speed set incorrectly
1) Ensure that VAC is above 108 VAC
2) Reduce load or increase motor size
3) Replace brushes
4) Consult “Trim Pot Adjustments” section

1) Too much IR Comp
2) Motor is in Current Limit
3) Motor not pulling enough current
4) Max trim pot set too high
5) Motor speed is above rated speed
1) Consult “Trim Pot Adjustments” section
2) Consult “Trim Pot Adjustments” section
3) Motor current must be greater than 150 mA (DC)
4) Consult “Trim Pot Adjustments” section
5) Reduce speed

1) Low voltage
2) Overload condition
3) Worn motor brushes
4) Defective motor bearings
5) Defective electrical components
1) Ensure that VAC is above 108 VAC
2) Reduce load
3) Replace brushes
4) Replace bearings
5) Contact distributor or representative


1) Incorrect wiring (enclosed drive)
2) Defective wiring
3) Jumper inhibit
4) Defective component
1) Ensure that Terminal Strip Wiring is correct per
wiring instructions/diagrams (check AC line
connection in particular)
2) Check wiring
3) Check jumper inhibit pin connection (P2)
4) Contact AutomationDirect “Product Returns” for
replacement.

Page 15IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020


Optional analog voltage or current input card for open-frame GSD5-240-10C series DC drives only
This option card allows for the use of either a grounded or non-grounded remote DC signal such as
0–5 VDC through 0–250 VDC, 4–20mA, or a remote speed potentiometer. The DC input signal type can
be selected for voltage (Vin) or current (4–20mA) via the JP2 jumper clip. There is a Hi/Lo range jumper
(P4) selection that should be set to the (Lo) setting when using a 4–20mA signal or voltage ranges of
0–5 VDC through 0–25 VDC. When using voltage ranges of 0–25 VDC through 0–250 VDC, this jumper
must be set to (Hi). The GAIN trim pot is used to set full linear output in reference to the input signal
range. The output of this remote signal isolation board is a linear signal that is proportional to the
remote input signal being supplied.

AC1 AC2
-ARM +ARM
CUSTOMER
SIGNAL
CUSTOMER
COMMON
MIN MAX ACCEL IR COMP CUR LIM
JU2
POT LO
AC
P1
P2
JU4
P4
P3
JP2
-1
-2
-3
4-20
Vin
-1 -2 -3
ORANGE
RANGE
JUMPER
CONNECTOR GAIN
TRIMPOT
Vin or 4-20mA
CONNECTOR
GSD5-240-10C with
GSDA-AI-V5 installed
JU3 JU1 JU5
The Kit Includes:
• (1) option card
• (3) spacers (0.25 x 0.5 in)
• (3) Phillips-head screws (#6-32 x 0.75
in)
Spacers:
Install spacers at JU1, JU3, and JU5, as
illustrated.
Wiring Jumpers:
Connect wires JU2 and JU4 as
illustrated.

1) With motor connected and NO power at the drive, connect a DC voltmeter (meter must not be
grounded) to control outputs as follows: Meter COMMON to the -ARM terminal; Meter POSITIVE
to the +ARM terminal. Select correct meter range (0-90V or 0-180V).
2) Preset GAIN trim pot (analog voltage follower board) fully CCW, place range jumper clip in proper
position.
3) Preset control as follows: MIN and IR COMP fully CCW; MAX at 50%.
4) Apply desired AC voltage to drive and analog voltage follower board.
5) With 0 volts into analog voltage follower board, adjust MIN trim pot on drive to eliminate
deadband. To do this, increase MIN fully CW, and then adjust CCW until meter reads 0V.
6) Apply maximum input voltage to analog voltage follower board input.
7) Adjust GAIN until no further change in voltage output occurs, then turn CCW until a 5V drop
occurs, and then set control MAX to 90VDC (for 120V input) or 180VDC (for 240V input).
8) For Closed Loop systems the IR COMP should remain fully CCW. For Open Loop systems, set IR
per set-up procedure.
9) Some interaction between trimpots may occur. Recheck the MIN trim pot setting and repeat steps 5
through 7 as needed.

Page 16 IronHorse GSD5 DC Drives User Manual – 1st Ed, Rev E – 05/13/2020
Literature Number: LT141
Drawing Number: A-5-3903E